1994 SLT 750 Fuji Rebuild

I recently picked up a new project; rebuilding my SLT 750 fuji jet ski. This ski has some great memories, and by that I mean by the end of last summer I wanted to blow it up. My last trip to the lake with the ski, it caught fire. I had recently replaced the water cooler gasket on the pto cylinder. It ran great for about 10 minutes then stopped working. I got the ski up to shore and began to troubleshoot, which didn't result in anything good; the ski caught fire. The summer before that, the ski took off across the lake and hit rocks damaging the hull. Long story short, I bent God's ear talking about that ski.

So anyways, I decided to try the ski out again; but this time do it right and rebuild the whole thing. I started by taking the gas, oil, battery, and front bin out.
As you can see there is some oil in the bottom of the jet ski.. I'm still curious as to what started the fire last summer, whether it was this or gas fumes.. Then I began with pump removal.. Easy.
I'm not quite sure why I did this.. but what the hell. Then I began with the intake removal to get to the carbs, in which I plan to rebuild. I haven't fully removed these, I'm having trouble getting to the very last bolt on the PTO cylinder. Any suggestions for this?
You know how your not suppose to get to mad at a project, just take a break and everything? Well, I decided to be an idiot and try to take out the 14 bolts connecting the carbs to the cylinders. I broke a few tools in the process, and the few that I threw I couldn't find. As I had trouble taking out that last bolt I skipped and plan to try again tomorrow. I went to the exhaust removal..
I've also taken out the upgraded gas pump, I plan on replacing all fuel lines also.. Suggestions for these? I haven't taken those out yet though. Does anyone have any suggestions on repairing the hull? I'm going to get everything out and repair the bottom of the hull, as it has a small leak. I also want to repaint the ski, any suggestions? Thanks for all the help, and for looking! I want to do this right! So any help or constructive criticism is appreciated!

I'm not quite sure why I did this.. but what the hell. Then I began with the intake removal to get to the carbs, in which I plan to rebuild. I haven't fully removed these, I'm having trouble getting to the very last bolt on the PTO cylinder. Any suggestions for this?

Get a short ratcheting closed end wrench - makes it much easier

Originally Posted by Carson

You know how your not suppose to get to mad at a project, just take a break and everything? Well, I decided to be an idiot and try to take out the 14 bolts connecting the carbs to the cylinders. I broke a few tools in the process, and the few that I threw I couldn't find. As I had trouble taking out that last bolt I skipped and plan to try again tomorrow. I went to the exhaust removal..

Gotta get the carbs out first, then the intake manifold is easy

Originally Posted by Carson

I've also taken out the upgraded gas pump, I plan on replacing all fuel lines also.. Suggestions for these? I haven't taken those out yet though. Does anyone have any suggestions on repairing the hull? I'm going to get everything out and repair the bottom of the hull, as it has a small leak. I also want to repaint the ski, any suggestions? Thanks for all the help, and for looking! I want to do this right! So any help or constructive criticism is appreciated!

IMHO, you can find a donor hull of that model much cheaper than repair/repaint (unless you are wanting to customize the paint job)

Haha, that is so true. Does anyone know a reason the fire could have started?

Originally Posted by TBone14

Originally Posted by Carson

I'm not quite sure why I did this.. but what the hell. Then I began with the intake removal to get to the carbs, in which I plan to rebuild. I haven't fully removed these, I'm having trouble getting to the very last bolt on the PTO cylinder. Any suggestions for this?

Get a short ratcheting closed end wrench - makes it much easier

Originally Posted by Carson

You know how your not suppose to get to mad at a project, just take a break and everything? Well, I decided to be an idiot and try to take out the 14 bolts connecting the carbs to the cylinders. I broke a few tools in the process, and the few that I threw I couldn't find. As I had trouble taking out that last bolt I skipped and plan to try again tomorrow. I went to the exhaust removal..

Gotta get the carbs out first, then the intake manifold is easy

Originally Posted by Carson

I've also taken out the upgraded gas pump, I plan on replacing all fuel lines also.. Suggestions for these? I haven't taken those out yet though. Does anyone have any suggestions on repairing the hull? I'm going to get everything out and repair the bottom of the hull, as it has a small leak. I also want to repaint the ski, any suggestions? Thanks for all the help, and for looking! I want to do this right! So any help or constructive criticism is appreciated!

IMHO, you can find a donor hull of that model much cheaper than repair/repaint (unless you are wanting to customize the paint job)

Okay, let's say I don't repaint it.. would it still be harder to repair it rather than purchase another hull and put the engine in there? That just sounds pretty complicated.

Depending on what you want to do - plan on at least $250 to paint a ski (if you want to do it right) - probably more if you want to customize

Post a pic of the damage

I will when I get everything out of ski. The holes not any bigger than a golfball, but I will have to sand it down some because I've already tried rubber spray and a fiberglass repair kit. But, there was also water in the bottom of the ski when I did this. So I believe that if I clean the ski out inside and out, and repair it correctly instead of half-assing it, it'd work. That is where I went wrong with this ski, half-assing and just wanting it to be on the water. But I'm doing this correct now.

Originally Posted by BlueFishCrisis

You could just do the top deck to customize it, but I thought I had read you had bottom damage to fix and paint...... Up to you!

I could honestly care less about the bottom being painted. And honestly, I'd just paint the small part where it was damaged. So I'll do that anyways. I like the ski in your pro pic and signature. How much did it cost you to make yours look that nice? I really just want to clean my up.